Optimization Solutions from SIEMENSS
Instrumentation & Controls
SPPA-P3000
Solutions for Process Optimization
Siemens Power Plant Automation
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Power Generation
Optimization Solutions from SIEMENSS
Siemens Power Generation · Instrumentation & Controls,
the comprehensive solutions provider for the energy industry
The goals of the process optimization and the SPPA-P3000 Solutions.
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Optimization Solutions from SIEMENSS
Solutions for process optimization
High efficiency
Optimizing processes in the power plant is one
of the most demanding tasks of all. Especially
if it is to be achieved without costly modifications on the mechanical engineering side, i.e
without major conversions to the steam generator and turbine.
SPPA-P3000 Solutions improve overall efficiency by various efficiency enhancement approaches which include reduction of valve
throttling losses, optimization of combustion
air, steam temperature or of cooling water.
This purely software-oriented approach followed by Siemens has been an ongoing success in the world's power plants for just on a
decade now and has made many operators
happy people – especially when they think
about their ROI (return on investment).
Improved efficiency can be used to
either
• Reduce fuel costs for the same level of
power sales
or
• Increase revenue from additional
power sales for the same level of fuel
cost.
Besides being widely incorporated into new
power plants, the Siemens Power Plant Automation Solutions for Process Optimization
SPPA-P3000 are nowadays a popular choice
for power plant upgrades..
The most profitable operating point differs for
each plant and can even vary over time as a
function of market requirements.
SPPA-P3000 Solutions allow a power plant
unit to always be operated at the most profitable operating point, which calls above all for
greater flexibility and higher efficiency, better
availability and lower emissions.
High flexibility
SPPA-P3000 Solutions enable optimum response to load demands. Our control concepts
together with the extension of the operating
range of the subordinate controls to lower
minimum and higher maximum loads lay the
foundations for flexible and at the same time
stable operation.
Benefits:
•
•
Increased revenue by provision of additional primary and secondary control
capability.
Increased revenue or reduced financial
losses thanks to consistent start-up
capability, low cost start-up, reduced
minimum or increased maximum load
levels and fast response to changing
load requirements.
Benefits:
High availability
Implementation of model based feedforward
control in SPPA-P3000 Solutions allows fuel
overfiring to be reduced and the number of
control actions to be kept to an absolute minimum. This simultaneously reduces operating
life consumption effects on components.
Thanks to the tried and tested load capability
circuit, the plant avoids tripping on the loss of
major components.
Benefits:
• Reduced frequency of failures thanks
to low-stress operation
• Reduced frequency of trips as load
capability circuit enables plant to ride
loss of major components
Low emissions
SPPA-P3000 Solutions achieve a reduction in
emissions through stable plant operation and
continuous operating point optimization for the
separate burners.
Any increase in efficiency yields a simultaneous reduction in CO2 emissions.
Benefits:
•
•
•
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Compliance with statutory emissions
limits and avoidance of financial penalties for violations of these
Revenue from sale of superfluous
emissions credits
Higher price can be realized for sale of
ash
Optimization Solutions from SIEMENSS
High flexibility
Fast Start
Get back on the grid faster
To get the unit back on the grid in the shortest
possible time without thermal stresses for
thick-walled components violating permissible
limits.
Fast Start minimizes startup time while ensuring that thermal stresses for thick-walled components do not violate permissible limits. In
most cases, a further bonus of reduced startup
time is a significant reduction in fuel consumption.
Fast Ramp
Respond reliably and fast to
market requirements
The faster a power plant unit can respond to
changing load situations, the higher the financial benefit it can reap.
Fast Ramp coordinates steam generator and
turbine, mobilizing stored energy in the power
plant process to give precise and repeatable
load changes.
Frequency Control
Increase range for frequency control
Minimum Load Reduction
Reduce minimum load level
A particular feature of oil- and gas-fired units is
that there are certain times of day when power
prices can fall below their generating costs.
There are a number of considerations that may
rule out shutdown of units under these conditions, such as when the units involved feature
district heat extraction and are thus subject to
the stringent requirements imposed for security
of supply for district heat.
Minimum Load Reduction reduces the minimum load level for a unit, and thus minimizes
the financial losses sustained in such periods
of unprofitable operation.
Maximum Load Plus
Increase electrical output to
above 100%
There are times when the price for power on
the spot market is so high that it can be extremely lucrative for plant owner/operators to
operate their plants loads in excess of 100 %.
Maximum Load Plus enables maximum output to be increased above 100% for unchanged main steam mass flow by smooth and
controlled partial or full deactivation of the HP
feedwater heaters.
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Provision of primary frequency control and
spinning reserve is becoming a steadily more
lucrative service. Due to the fast load ramps
that this service requires, it places very high
demands on the dynamic control response of a
power plant unit.
Frequency Control enables reliable and costeffective provision of primary frequency control
and spinning reserve.
Dispatch Control
Increase window for dispatcher
control
Load cycling under grid dispatcher control for
provision of secondary frequency control capability (ADS/AGC, etc.) is becoming a steadily
more lucrative service. Due to the fast load
ramps that this service requires, it places very
high demands on the dynamic control response of a power plant unit.
Dispatch Control enables reliable and costeffective provision of secondary frequency control capability.
Optimization Solutions from SIEMENSS
High efficiency
Low Loss Start
Start-up with minimum losses
Startup of a plant unit is a costly process, as
no power sales are possible for its duration
with utilization of premium fuels such as oil and
gas necessary even in the case of coal-fired
units.
Low Loss Start minimizes fuel consumption
during the startup process while ensuring that
thermal stresses for thick-walled components
do not violate permissible limits. In most cases,
a further bonus in addition to reduced fuel consumption is a significant reduction in startup
time.
Best Point
Operate plant at optimum
operating point
It is often difficult to identify departures from
the optimum operating point for a power plant.
The cost penalties incurred as a result likewise
often remain unknown.
Best Point performs continuous analysis,
monitoring and optimization of the overall
process and key components. It supplies information about any departure from optimum
conditions, calculates the resulting costs and
highlights improvement potential.
Sootblower Optimizer
Optimize operation of sootblowers
The optimum point at which to perform sootblowing is set by the constraints of minimizing
costs for soot blowing and the losses caused
by fouling of heat exchange surfaces.
Sootblower Optimizer calculates the optimum
point for sootblowing for each separate sootblower group as a function of current condition
of the associated heat exchange surfaces.
Combustion Optimizer
Increase efficiency, lower emissions
The optimum operating point for a burner firing
coal depends on a number of factors. The central one is pulverized coal flow to the burner, a
parameter not easily measured, with the condition of the burner and of the pulverizers also
having an impact here.
Combustion Optimizer measures pulverized
coal flow admitted to a burner, optimizing operation of the separate burners on this basis.
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Temperature
Optimizer
Increase temperatures close
to limits
Reliably holding superheat and reheat
steam temperatures
at their setpoint is of
decisive importance
both for plant efficiency and for plant
capability to perform
fast load changes.
Temperature Optimizer optimizes control action by the
various final control
elements used for
temperature control
during startup and
over the entire load
range. These include
spray attemperators,
flue gas recirculation
control elements,
biflux and triflux control valves, flue gas
backpass dampers
and tilting burners.
The lower-level temperature controls ensure
that temperatures will be reliably held at their
setpoints.
Fuel Optimizer
Operate efficient and reliable despite firing of different fuels
Firing of low-cost supplementary fuels and of
fuels with widely fluctuating properties place
stringent demands on the control systems of a
power plant. This is particularly the case for the
load and air control systems for the steam
generator.
Fuel Optimizer allows minimization of fuel
costs while at the same time ensuring stable
operation of the power plant unit.
Low Throttling
Reduce throttling losses
Low Throttling reduces the degree of throttling for turbine valves, feedwater control
valves and fan vanes for forced- and induceddraft fans to the amount actually needed to
permit these to meet dynamic response requirements without any negative impact on
load flexibility.
Optimization Solutions from SIEMENSS
High availability
Runback Plus
Ride out loss of major components
In the event of loss of a major component such
as a feedwater pump or induced-draft fan,
Runback Plus then automatically performs
stable and reliable fast runback of the plant to
the new maximum level that is permissible
without the component concerned. This action
allows the unit to ride out this condition, avoiding an outage of the entire unit.
Life Time Plus
Increase availability through
low-stress operation
Regardless of all the demands for high efficiency and flexibility, low-stress operation remains a fundamental requirement.
Thanks to its model based and predictive feedforward control and mobilization of stored energy, Life Time Plus enables stable and precise load changes with minimum fuel overshoot. This minimizes wear and tear on plant
components.
Low emissions
Emissions Control
Lower emissions
Ever more stringent environmental legislation
demands the reduction of power plant emissions. The introduction of trading in emission
credits for a number of pollutants even opens
up potential for deriving financial benefit from
emission reduction by selling excess emission
credits.
Emissions Control continuously measures
emissions and reduces these by precise adjustment of fuel and air flow together with optimum settings for the separate burners.
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Optimization Solutions from SIEMENSS
The basis: excellent control concepts
Excellent control concepts are at the base of P3000 Solutions. Consistent use of model-based, predictive feedforward structures, exploitation of inherently stable processes and decoupling of highly intermeshed subprocesses yields optimum operating behavior. As a result, operating behavior is extremely
stable, but still features flexible and fast response. These properties lay the foundation stone for high
profitability.
High profitability
High
flexibility
High
efficiency
High
availablity
Low
emissions
Optimum operating behavior
High
repeatability
High
stability
High
control quality
Control fundamentals
Model-based
feedforward
Prediction
Intrinsic stability
Decoupling
Selected references for SPPA-P3000 Solutions
Parish, USA
Low Loss Start
Minimum Load Reduction
Fast Ramp
ValesPoint, Australia
Fast Ramp
Temperature Optimizer
Minimum Load Reduction
Low Throttling
Callide, Australia
Fast Ramp
Maximum Load Plus
Temperature Optimizer
Dispatch Control
Niederaussem, Germany
Fast Ramp
Frequency Control
Dispatch Control
Lippendorf, Germany
Fast Ramp
Temperature Optimizer
Frequency Control
Karlsruhe, Germany
Fast Ramp
Fast Start
Frequency Control
Dispatch Control
Simmering, Austria
Low Loss Start
Temperature Optimizer
Low Stress
Dispatch Control
Plomin, Croatia
Fast Start
Temperature Optimizer
Fast Ramp
Frequency Control
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Optimization Solutions from SIEMENSS
Instrumentation & Controls
Published by
and Copyright 2006:
Siemens AG
Power Generation
Instrumentation & Controls
Siemensallee 84
D-76187 Karlsruhe
Phone: (+ 49) 7 21 / 5- 69 43
Fax.: (+ 49) 7 21 / 5 95- 67 21
E-Mail: contact-pgl1@siemens.com
www.siemens.de/ic
Subject to change without prior notice.
The information in this document contains general
descriptions of the technical options available which
do not always have to be present in individual cases.
The required features should therefore be specified
in each individual case at the time of closing the
contract.
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Overview “SPPA-P3000 Solutions
for Process optimization”
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Power Generation